Cosmetic applicators and methods of manufacture

ABSTRACT

A molded plastic applicator for cosmetics, such as a mascara brush, including an integral molded plastic panel that lies substantially in a mold plane when formed and is bent out of the mold plane to surround an extended longitudinal axis when the applicator is assembled. A plurality of openings, or projections such as bristles, are formed in or on the panel so as to be oriented substantially in a common pull direction transverse to the mold plane when the panel lies in the mold plane and to be oriented substantially radially of the longitudinal axis in directions distributed around the axis when the panel is bent to surround the axis. A retainer holds the panel bent out of the plane in surrounding relation to the axis. The panel may be formed as a plurality of free-ended limbs, radiating from a hub through which the longitudinal axis extends, and bent down around the axis; alternatively, it may be generally rectangular as formed, and bent into a cylinder about the axis, or it may be formed as a band that is wound helically about the axis. A method of making the applicator includes steps of molding the panel, bending the panel about the axis, and retaining the panel in the bent configuration.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a continuation of copending U.S. patent application Ser. No.11/893,150 filed Aug. 14, 2007 (now allowed), which claims the benefit,under 35 U.S.C. §119(e), of U.S. provisional patent applications No.60/838,973, filed Aug. 16, 2006, and No. 60/853,378, filed Oct. 20,2006, the entire disclosures of all of which are incorporated herein bythis reference.

BACKGROUND OF THE INVENTION

This invention relates to applicators for cosmetics, such as moldedplastic applicators, and to methods of making them. In one importantsense, to which detailed reference will be made herein for purposes ofillustration but without limitation, the invention is particularlydirected to brushes for applying mascara or the like.

Brushes of the type commonly referred to as “twisted-in-wire” brushes,constituted of fibers clamped at their midpoints in a twisted wire core,are well known and widely used in the cosmetics industry. Althoughacceptable for uses exemplified by the application of mascara, thesebrushes have certain disadvantages. They are relatively costly, andthere are only a limited number of suppliers. Moreover, a conventionaltwisted-wire brush offers essentially only one kind of brush profile foruse both to transfer mascara from a container to the face and to applythe mascara to the eyelashes. To improve application, it would bebeneficial to provide mascara brushes having other structures; but thediversity of possible configurations of twisted-in-wire brushes isrestricted by the requirement to trim the bristles in order to achievedesired shapes, and the difficulty of forming and positioning cutters toeffect such trimming.

It has also been proposed heretofore to employ plastic brushes and combsas mascara applicators. Injection molded product suppliers are quiteabundant, the cost of a molded brush can be less than that of atwisted-in-wire brush, and a wide variety of designs is theoreticallypossible. The production of molded plastic brushes with radiatingbristles distributed around a cylindrical or like core, however, hasbeen attended with substantial difficulties in separating the brush fromthe mold, owing to interference between the divergently angled brushfibers and the mold recesses provided for forming them, unless specialand complex multi-part mold structures are employed.

SUMMARY OF THE INVENTION

The present invention, in a first aspect, broadly contemplates theprovision of an applicator for cosmetics or the like, comprising asupport element transformed from an extended configuration to a bentconfiguration; and a plurality of features comprising projections oropenings or mixtures thereof, provided in an initial orientationrelative to each other in or on the support element in the extendedconfiguration, at least some of the features being reoriented relativeto others of the features when the element is transformed into the bentconfiguration.

This construction, in which the support element is transformed from oneconfiguration to another while at least some of the provided featuresare reoriented relative to each other, facilitates the utilization ofmanufacturing processes that afford a desirable diversity of shapes andarrangements of applicator features but have heretofore been attendedwith difficulties such as those discussed above.

As particularly exemplified by molded plastic applicators for cosmeticsor the like, an applicator in accordance with the invention may comprisean integral molded plastic panel lying substantially in a mold planewhen formed and bent out of the mold plane to surround an extendedlongitudinal axis; and a plurality of features formed in or on thepanel, oriented substantially in a common pull direction transverse tothe mold plane when the panel lies in the mold plane and orientedsubstantially radially of the longitudinal axis in directionsdistributed around the axis when the panel is bent to surround the axis.The term “features” embraces both projections and openings, andincludes, without limitation, projections such as bristles, tines orfibers, as well as holes, cavities and slots. Further in accordance withthe invention, in illustrative or preferred embodiments thereof, aretainer is provided, holding the panel bent out of the plane insurrounding relation to the axis.

The terms “mold plane” and “pull direction” are used herein withreference to conventional types of molds, such as injection molds, forproducing plastic articles, characterized in having relatively movableshaped mold surfaces that face each other on opposite sides of anotional plane (“mold plane”) and, in the course of a molding operation,move relatively toward and away from each other in a direction (“pulldirection”) perpendicular to the plane. When the mold plates are broughttogether, the respective shaped mold surfaces meet and cooperativelydefine a volume that is filled with plastic material, thereby to moldthe material into an article having the configuration of the definedvolume. The initial substantially planar configuration of the panel andthe initial substantially parallel pull-direction orientation of thefeatures formed therein or thereon, in the applicators of the invention,facilitates separation of the molded article from the applicator, whilethe subsequent bending of the panel around a longitudinal axistransforms the article into an applicator having, e.g., a generallycylindrical or conical core with features exemplified by bristles orfibers distributed all around and projecting generally radially from thecore, in the illustrative case of a mascara brush or the like, therebyovercoming the difficulty of molding such brushes without need forcomplex molding equipment.

In particular embodiments, the panel comprises a plurality of relativelyrigid portions interconnected by relatively flexible hinge portions toenable bending of the panel out of the mold plane to surround thelongitudinal axis without substantial deformation of the relativelyrigid portions.

Thus, the panel may include a hub portion in register with thelongitudinal axis, which is transverse to the mold plane, and therelatively rigid portions may comprise a plurality of limbs extendingradially from the hub portion when the panel is lying substantially inthe mold plane, each limb having a free end and a second end, with thehinge portions respectively connecting the second ends of the limbs tothe hub portion of the panel such that the limbs are bendable relativethereto so as to be parallel to and surround the axis. The limbs mayrespectively have surfaces facing away from the axis when the limbssurround the axis, and the features may be projections formed on andextending from the surfaces of the limbs. Alternatively, the featuresmay be openings formed in and extending along the respective limbs, andthe applicator may further include a plurality of projections formed inthe openings by insert molding so as to extend away from the axis. Theapplicator of the invention, in these embodiments, may also include anelongated stem molded integrally with, and extending along the axisfrom, the hub portion such that the limbs when bent surround the stem;and the retainer may engage the free ends of the limbs to hold them insurrounding relation to the stem.

In other embodiments of the invention, the relatively rigid portions areparallel to each other and to the axis when the panel lies substantiallyin the mold plane, and the hinge portions are disposed between andparallel to the relatively rigid portions for bendably interconnectingadjacent ones of the relatively rigid portions. The features may beopenings formed in the relatively rigid portions, with the applicatoralso including projections inserted in and extending outwardly throughthe openings when the panel surrounds the axis. To provide suchprojections, the applicator may have a second integral molded plasticpanel lying substantially in a mold plane when formed and bent out ofthe last-mentioned plane to surround the longitudinal axis inwardly ofthe first-mentioned panel, the second panel bearing the projections.

In still further embodiments, the panel is sufficiently flexible so asto be bent around the aforesaid axis with substantially continuoussurface curvature, and the features are projections formed on andextending outwardly from the bent panel. For instance, the panel may beinitially formed as a rectangle which is bent into a substantiallycylindrical configuration with two long edges of the panel parallel toeach other and to the axis, and may be provided with relatively rigidmembers respectively extending along these long edges in abuttingrelation to each other when the panel is in the cylindricalconfiguration, the retainer comprising an element holding the rigidmembers together.

In additional embodiments, the panel comprises an elongated band havinga surface, the features are projections extending from this surface, andthe band is bent into a helix around the aforesaid axis with theprojection-bearing surface facing outwardly. The retainer may include asubstantially rigid core extending along the axis and engaging the bandto support and maintain the helix, or it may comprise a wire extendinglongitudinally through the band, the wire being twisted helically toform and maintain the helix and the band being molded around the wire.

In another aspect, the invention embraces a method of making anapplicator for cosmetics or the like, comprising providing a bendablesupport element in an extended configuration, providing in or on thesupport element, while the support element is in the firstconfiguration, a plurality of features comprising projections oropenings or mixtures thereof having an initial orientation relative toeach other, and transforming the support element from the firstconfiguration into a second configuration by bending to constitute abase or core of the applicator, thereby reorienting at least some of thefeatures relative to others of the features.

Again as exemplified by the manufacture of molded plastic applicators,this method may comprise molding an integral and bendable plastic panellying substantially in a mold plane and having a plurality of featuresformed in or on the panel and oriented substantially in a common pulldirection transverse to the mold plane, these features being at leastone of projections and openings; and bending the panel out of the planeto surround an extended longitudinal axis such that the features areoriented substantially radially of the axis in directions distributedaround the axis. The panel may then be engaged by a retainer to hold thepanel bent out of the plane and in surrounding relation to the axis.

Further, the invention embraces a molded plastic applicator forcosmetics or the like, comprising a molded plastic panel initially lyingsubstantially in a mold plane and being transformed to a bentconfiguration at least partially out of the mold plane, and a pluralityof features formed in or on the panel, initially oriented in at leastone of (i) a substantially common pull direction transverse to the moldplane and (ii) the mold plane, at least some of the features beingreoriented relative to others of the features when the panel istransformed to the bent configuration, and wherein any featuresinitially oriented in the substantially common pull direction areprojections or openings and any features initially oriented in the moldplane are projections.

In accordance with the invention, the panel can be molded around anelongated bendable and shape-holding insert, the panel initially lyingsubstantially in a mold plane and being transformed to a bentconfiguration at least partially out of the mold plane by bending theinsert to the bent configuration. In particular embodiments, thefeatures are projections, the insert is a wire having opposed ends, andthe panel is transformed into the bent configuration by a processcomprising bending the wire into substantially a U shape havingsubstantially parallel legs and twisting the legs about each other.

Also in accordance with the invention, the features can be projectingbristles configured (e.g., with noncircular cross-sections) so as tohave greater flexibility in a first direction transverse to theirlengths than in a second direction transverse to their lengths.

Further features and advantages of the invention will be apparent fromthe detailed description hereinafter set forth, together with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a highly simplified and schematic fragmentary elevationalsectional view of a mold for forming a molded plastic articleillustrative of the panel and associated features of the applicator ofthe present invention;

FIG. 2 is a similarly simplified schematic perspective view of a moldedplastic article produced by the mold of FIG. 1, with the panel of thearticle lying in the mold plane;

FIG. 3 is a perspective view of the article of FIG. 2 as bent tosurround an extended longitudinal axis;

FIG. 4 is a cross-section of the article as bent in FIG. 3;

FIG. 5 is a perspective view of an applicator embodying the invention ina particular form, with the panel lying in a mold plane;

FIG. 6 is a perspective view of the applicator of FIG. 5 at anintermediate stage in bending the panel out of the mold plane;

FIG. 7 is a perspective view, partly exploded, of the applicator of FIG.5 with the panel fully bent to surround an extended longitudinal axis,also illustrating the retainer and handle of the applicator;

FIG. 8 is a view, similar to FIG. 5 but partly exploded, of a modifiedform of the applicator of FIG. 5;

FIGS. 9 and 10 are enlarged fragmentary perspective views illustratingtwo alternative types of projection-bearing inserts for the applicatorof FIG. 8, mounted in a limb of the applicator;

FIG. 11 is a cross-sectional view of the limb-mounted insert of FIG. 9;

FIGS. 11A, 11B and 11C are similar views of modified structures of thelimb-mounted insert of FIG. 9;

FIG. 12 is a cross-sectional view of the limb-mounted insert of FIG. 10;

FIG. 13 is a plan view of the outer panel of another embodiment of theinvention, shown as lying in a mold plane;

FIG. 14 is an exploded cross-sectional view, taken as along line A-A ofFIG. 13, of the outer and inner panels of the applicator of FIG. 13,both shown as lying in mold planes;

FIG. 15 is a view similar to FIG. 14 showing the outer and inner panelsin assembled relation but still lying in mold planes;

FIGS. 16 and 17 are cross-sectional views, respectively taken as alonglines A-A and B-B of FIG. 13, of the applicator of FIG. 13 bent tosurround an extended longitudinal axis;

FIG. 18 is an exploded perspective view of outer and inner panels of afurther embodiment of the applicator of the invention, both lying inmold planes;

FIGS. 19 and 20 are enlarged fragmentary elevational sectional views,respectively, of portions of the inner panels of the embodiments ofFIGS. 13 and 18, illustrating the difference between types ofprojections used in these two embodiments;

FIG. 21 is a fragmentary perspective view of a portion of the innerpanel of FIG. 18, taken as along line A-A of FIG. 18;

FIG. 22 is an exploded perspective view of yet another embodiment of theapplicator of the invention;

FIG. 23 is a perspective view of the panel of the applicator of FIG. 22,lying in a mold plane;

FIG. 24 is a cross-sectional view of the panel of FIG. 23, lying in themold plane;

FIG. 25 is a cross-sectional view of the same panel, bent to surround anextended longitudinal axis;

FIG. 26 is an exploded perspective view of a still further embodiment ofthe applicator of the invention;

FIG. 27 is a cross-sectional view of the panel of the applicator of FIG.26, lying in a mold plane;

FIG. 28 is a cross-sectional view of the panel of FIG. 27, bent tosurround an extended longitudinal axis;

FIG. 29 is a longitudinal sectional plan view of the applicator of FIG.26, fully assembled for use;

FIG. 30 is a perspective view of the panel of another embodiment of theinvention, lying in a mold plane;

FIG. 31 is an exploded perspective view of the applicator of FIG. 30with the panel bent to surround an extended longitudinal axis;

FIG. 32 is an exploded perspective view of a further embodiment of theinvention, before the panel is bent;

FIG. 33 is a view similar to FIG. 32 but showing the panel being bent;

FIGS. 34, 35 and 36 are perspective views of a modified form of theapplicator of FIG. 32, illustrating successive stages in assembling theapplicator;

FIG. 37 is a view similar to FIG. 36 illustrating an alternative corestructure for the applicator;

FIGS. 38 and 39 are enlarged fragmentary perspective views illustratingtwo exemplary arrangements of projections for the embodiments of FIGS.32 and 34;

FIG. 40 is a fragmentary perspective view of the panel of a furthermodified form of the applicator of FIG. 32, at a first step in bendingof the panel;

FIG. 41 is a view similar to FIG. 40 showing an intermediate stage inbending of the panel;

FIG. 42 is a fragmentary perspective view of a portion of the panel ofFIG. 40;

FIG. 43 is a cross-sectional view of the same panel, taken along lineA-A of FIG. 42;

FIG. 44 is a somewhat schematic perspective view of the applicator ofFIG. 40, with the panel lying in a mold plane, illustrating a particularbristle arrangement;

FIGS. 45, 46, 47 and 48 are schematic side views illustrating successivestages in bending the panel of the FIG. 40 applicator;

FIG. 48A is a flow chart of the process of forming an applicator of thetype of FIG. 48 from an as-molded panel of the type of FIG. 45;

FIGS. 49 and 50 are schematic side views, respectively corresponding toFIGS. 46 and 48, illustrating successive stages in bending a modifiedform of the applicator;

FIG. 51 is a schematic side sectional view of a further embodiment ofthe invention, incorporating a panel of the general type shown in FIG.40;

FIGS. 52, 53 and 54 are perspective views of a further modified form ofthe applicator of FIG. 32, illustrating successive stages in assemblingthe applicator;

FIGS. 52A, 53A and 54A are schematic side views of successive stages inassembling a modified form of the applicator of FIG. 54;

FIG. 55 is a perspective view illustrating an alternative band structurefor the applicator of FIGS. 52-54;

FIGS. 56A, 56B and 56C are sectional views respectively taken alonglines A-A, B-B and C-C of FIG. 55;

FIGS. 57A, 57B and 57C are fragmentary plan views of the portions of theband of FIG. 55 respectively shown in section in FIGS. 56A, 56B and 56C;

FIG. 58 is an exploded perspective schematic view illustrating a furthermodification of the applicator of FIG. 32;

FIGS. 59A, 59B, 59C, 59D, 59E and 59F are sectional views respectivelytaken along lines A-A, B-B, C-C, D-D, E-E and F-F of FIG. 58;

FIG. 60 is a simplified perspective view of another panel for use inmaking an applicator in accordance with the invention;

FIG. 61 is an enlarged cross-sectional view of the panel of FIG. 60;

FIGS. 62, 63, 64 and 65 are perspective views of various applicatorsmade by bending the panel of FIG. 60;

FIG. 66 is an enlarged cross-sectional view taken along line A-A of FIG.65;

FIG. 67 is an enlarged cross-sectional view of another panel for use inmaking an applicator in accordance with the invention;

FIG. 68 is a perspective view of the panel of FIG. 67;

FIG. 69 is an enlarged cross-sectional view of yet another panel for usein making an applicator in accordance with the invention;

FIG. 70 is a perspective view of the panel of FIG. 69;

FIGS. 71 and 72 are perspective views illustrating successive stages information of a still further panel for use in making an applicator inaccordance with the invention;

FIGS. 73A, 73B and 73C are sectional views of the molded panel of FIG.72, respectively taken as along lines A-A, B-B and C-C of FIG. 71;

FIG. 74 is a perspective view of an applicator embodying the invention,produced by bending or folding the panel of FIG. 72;

FIGS. 75A, 75B and 75C are sectional views respectively taken as alonglines A-A, B-B and C-C of FIG. 74;

FIG. 76 is a perspective view of another panel for use in making anapplicator in accordance with the invention;

FIG. 77 is a sectional view taken along line A-A of FIG. 76;

FIG. 78 is a sectional view taken along line B-B of FIG. 79;

FIG. 79 is a perspective view of an applicator embodying the invention,produced by bending or folding the panel of FIG. 76;

FIG. 80 is a perspective view of a further panel for use in making anapplicator in accordance with the invention;

FIG. 81 is a sectional view taken along line A-A of FIG. 80;

FIG. 82 is a perspective view of an applicator embodying the invention,produced by bending or folding the panel of FIG. 80;

FIG. 83 is a sectional view taken along line B-B of FIG. 82;

FIG. 84 is a perspective view of another panel for use in making anapplicator in accordance with the invention;

FIG. 85 is a plan view of the panel of FIG. 84;

FIG. 86 is a cross-sectional view of the panel of FIG. 85;

FIG. 87 is a side view of the panel of FIG. 85 after performance of afirst, folding step to transform the panel into an applicator embodyingthe invention;

FIG. 88 is a cross-sectional view of the panel of FIG. 87;

FIG. 89 is a side view of the panel of FIG. 85 after performance of asecond, bending step to complete the transformation of the panel intothe applicator;

FIG. 90 is a cross-section of the applicator of FIG. 89;

FIG. 91 is a perspective view of the applicator of FIG. 89;

FIG. 92 is a perspective view of another applicator embodying theinvention;

FIG. 93 is a cross-sectional view of one run of the applicator of FIG.92;

FIG. 94 is a view, similar to FIG. 93, of a modified form of theapplicator of FIG. 92;

FIGS. 95, 96 and 97 are schematic side sectional views illustratingsuccessive stages of forming tufts of bristles along a limb of anapplicator of the general type shown in FIGS. 5-12;

FIGS. 98, 99 and 100 are schematic side sectional views in illustrationof successive stages of one embodiment of procedure for forming tufts ofbristles along a limb of an applicator of the general type shown inFIGS. 18 and 20-21;

FIGS. 101, 102 and 103 are schematic side sectional views inillustration of successive stages of another embodiment of procedure forforming tufts of bristles along a limb of an applicator of the generaltype shown in FIGS. 18 and 20-21;

FIGS. 104 and 105 are enlarged fragmentary isometric views of anapplicator of the type shown in FIG. 7, illustrating a modified bristleconfiguration and respectively showing two different bristlearrangements;

FIG. 106 is a view illustrating the applicator of FIG. 105 in use,applying mascara to eyelashes;

FIG. 107 is an isometric view of a panel or band of the general typeshown in FIG. 40, with a modified bristle configuration similar to thatillustrated in FIGS. 104 and 105; and

FIG. 108 is a schematic side view of an applicator embodying theinvention, produced by transforming the band of FIG. 107 into a helix.

DETAILED DESCRIPTION

FIGS. 1-4 are schematic drawings illustrative of various terms andgeneral relationships pertinent to the applicator and method of thepresent invention in certain embodiments thereof. In particular, FIG. 1is a very simplified representation of pertinent features of aninjection mold 10 of a generally conventional type suitable for use toproduce molded plastic articles such as cosmetic applicators. The moldincludes upper and lower mold plates 11 and 12 that are relativelymovable toward and away from each other in a direction herein termed the“pull direction” and indicated by arrow D. The plates respectively havemold surfaces that face each other on opposite sides of a mold plane Pwhich is perpendicular to pull direction D, the surfaces beingconfigured as indicated at 14 and 15 to form projections and openings inthe molded article. When brought together, the mold surfacescooperatively define a mold cavity 16 to be filled with plastic materialto be molded.

The article produced in mold 10 is an integral molded plastic panel 18having the shape of the mold cavity 16 and lying substantially in themold plane P when formed. Features such as projections 20 (e.g.,bristles, tines or fibers) and/or openings 22 (e.g., cavities, holes, orslots) are formed on or in the panel, integrally therewith, in themolding process. In accordance with the invention, and as shown in FIG.2, these features are all oriented substantially in a common pulldirection transverse to the mold plane P when the panel lies in the moldplane; that is to say, in such condition of the panel, the directionsd₂₀ in which projections 20 extend and the directions d₂₂ in whichopenings 22 open are all substantially parallel to the pull direction Dperpendicular to the mold plane P.

By virtue of this arrangement, the mold plates are easily separated andthe produced article is easily removed or pulled from the mold withoutbeing impeded by interference between shaped portions of the moldsurfaces and features of the molded process. It is not essential thatthe as-formed panel be strictly planar or that the projections and/oropenings be strictly parallel to each other and to the pull direction,so long as the extent of departure from planarity or parallelism doesnot cause difficulty in opening the mold and removing the moldedarticle.

As shown in FIGS. 3 and 4, after being molded, the panel 18 is bent outof the mold plane so as to surround an extended longitudinal axis A,which is the axis of the final produced applicator. For example, thepanel 18 of FIG. 2 is so shaped that it can be bent or curled into asubstantially cylindrical shape with axis A as the geometric axis of thecylinder. When the panel is thus bent, the features (projections 20and/or openings 22) are oriented substantially radially of thelongitudinal axis A in directions distributed around the axis A. Thisarrangement is illustrated in FIG. 4, wherein lines R radiating fromaxis A (in a plane perpendicular thereto) at angularly spaced locationsaround the axis A are shown as coinciding with the directions in whichprojections 20 extend and the directions in which openings 22 open.Again, it is not essential that these directions strictly coincide withradii of the cylinder centered on axis A, so long as they are orientedin angularly different directions distributed around such a cylinder.

The article of FIGS. 2-4 exemplifies the way in which the presentinvention overcomes problems heretofore associated with the productionof cosmetic applicators such as mascara brushes having fibers orbristles radiating outwardly around the circumference of a cylindricalor conical core, viz., by initially molding an extended, generallyplanar panel bearing features such as bristles or fibers orientedsubstantially parallel to each other for ease of separation from themold, and then transforming the panel from an initial generally planarshape into a substantially cylindrical configuration wherein the fibersor bristles radiate outwardly at angles to each other around theperiphery of the cylinder.

FIGS. 5-7 illustrate an embodiment of the applicator of the inventionincluding a plastic panel 30 constituted of a small hexagonal centralhub portion 32, six long narrow limbs 34 of equal length radiatingoutwardly from the hub portion with adjacent limbs spaced 60° apart andeach having a free outer end 36, and six flexible hinge portions 38respectively joining the hub portion to the inner ends of the six limbs.The hub portion is the upper end of an elongated rectilinear plasticstem 40 of hexagonal cross-section. In the as-molded condition of thepanel, shown in FIG. 5, the hub portion, limbs and hinge portions liesubstantially in a common plane (the mold plane), while the stem extendsdownwardly from the mold plane in the pull direction, with itslongitudinal geometric axis substantially perpendicular to the moldplane. The hub, limbs, hinge portions and stem are molded integrally asa single unit.

Each of the limbs 34 has an upper surface bearing a multiplicity ofbristles 42 projecting therefrom in a direction (the above-defined “pulldirection”) that is substantially perpendicular to the mold plane whenthe limbs are lying in the mold plane as shown in FIG. 5; in suchcondition, the bristles on all six limbs are substantially parallel toeach other and also parallel to the aforementioned geometric axis of thestem. These bristles, illustrated as arranged in two parallel rows oneach limb (although alternative arrangements may be used), occupy amajor portion of the upper surface of each limb starting at the hingedinner end of the limb, but each limb also has a bristle-free outerportion 44 of the upper surface extending to the outer end 36. Thebristles may be molded integrally with the panel 30 and stem 40, or (asexplained below) they may be added to the panel limbs in a subsequentinsert molding operation.

Since the as-molded panel 30 including the hub portion, limbs and hingeportions lies substantially in the mold plane, while the stem 40 (andthe bristles 42, if formed in the same molding operation as the panel)are oriented substantially in the pull direction perpendicular to themold plane in the as-molded condition of FIG. 5, the entire unit can bemolded integrally in a generally conventional injection mold, and themold plates can be opened and the produced unit separated therefromwithout difficulty.

The substantially planar as-molded panel 30 of FIG. 5, with its attachedstem 40, is transformed into an assembled applicator 46 shown in FIG. 7,suitable for use as a mascara brush, by bending the six limbs 34downwardly relative to the hub portion 32 at their respective hingesuntil the limbs extend substantially parallel to, and snugly surround,the stem 40. An intermediate stage in this bending operation isillustrated in FIG. 6. During the course of assembly, each limb is bentthrough 90° from the mold plane about a bending axis, at its associatedhinge portion, that is parallel to one of the six sides of the hubportion; and each limb ultimately overlies and abuts one of the sixlongitudinal faces 48 of the stem. In the fully assembled condition ofFIG. 7, the outer surfaces of the limbs face away from the stem so thatthe bristles 42 are oriented substantially radially of the longitudinalaxis of the stem 40; i.e., they radiate outwardly from all sides of theapplicator 46 around the periphery thereof so as to form a completebrush.

The bristle-free outer end portions 44 of the folded limbs cooperativelyconstitute a shank portion 50 of the assembled brush, overlying andsurrounding the lower free end of the stem. This shank is inserted intothe open distal end 52 of a hollow shaft 54 that is mounted, at itsproximal end, in the cap 56 of a mascara container (not shown). Shaft 54serves as a retainer, holding the outer end portions 44 of the foldedlimbs together in the assembled condition in which the limbs of thepanel (and their outwardly radiating bristles) surround the stem axis.The relationship between the cap 56 and the applicator 46 is essentiallythe same as that between the cap of a mascara container and aconventional mascara brush; when the cap is threaded on the containerneck, the applicator 46 extends into the container interior, and whenthe cap is removed from the neck it is manipulated by the user as ahandle for applying mascara to the user's lashes with the brush.

As used herein, the terms “distal” and “proximal” refer respectively tothe brush end and handle/cap end of an applicator of the mascara brushtype.

Advantageously, to provide structural stability to the assembledapplicator, the limbs of the panel as well as the stems are maderelatively rigid, by appropriate selection of the plastic materialemployed and the dimensions chosen for the limbs and stem, while thehinge portions are made sufficiently thin to enable bending of the limbsthrough 90° at the hinges.

It may also be desired to form the bristles of a plastic materialdifferent from and softer than that of a panel and stem. To this end, asshown in FIG. 8, the limbs 34A of a panel 30A may be formed in theinitial panel-molding operation with elongated voids or slots 35 thatoccupy the same regions of the limbs as the bristles 42 in the panel 30of FIG. 5 and open in directions parallel to each other and to the stem40A, and substantially perpendicular to the mold plane in which thelimbs initially lie. Thereafter, while the limbs still lie in a commonmold plane, bristles 42A are formed in the slots 35 of all the limbs 34Aby an insert molding procedure, for example as inserts 43 with one ormore rows of plastic bristles 42A (FIGS. 9 and 11, 11A, 11B and 11C) oras inserts 45 bearing tufts of fibers 47 (FIGS. 10 and 12) similar tothe fibers of a conventional mascara brush. The as-molded bristles 42Aproject substantially in a common direction (the pull direction, asdefined above) while the limbs continue to lie in the mold plane. Aftermolding is complete, assembly of the applicator proceeds in the mannerillustrated in FIGS. 6 and 7.

As generally mentioned above, and as indicated in FIGS. 8-12, thebristles 42 a firmed on a limb may depart from strict parallelism witheach other and with the pull direction. Thus, when the bristles arearranged in two parallel rows along a limb, bristles of one of the rowsmay diverge from bristles of the other row, with each bristle beingoriented at an angle of e.g. 23° to the common pull direction. Suchdiverging bristles are within the meaning of the term “orientedsubstantially in a common pull direction” provided that they aresufficiently close to parallelism to enable the molded limb to be easilyseparated from its mold by relative movement of mold and limb in thecommon pull direction.

A second embodiment of the applicator of the invention is illustrated inFIGS. 13-17. The applicator includes an integral molded outer plasticpanel 60 of generally rectangular configuration as seen in plan viewwhen it is lying substantially in the mold plane (the plane of FIG. 13),constituted of a plurality of relatively rigid portions 62interconnected by relatively flexible hinge portions 64, the relativelyrigid portions being parallel to each other when the panel is lying inthe mold plane, and the hinge portions being disposed between andparallel to the relatively rigid portions for bendably interconnectingadjacent ones of the latter portions. The portions 62, as illustrated,may be formed as ribs of outwardly convex cross-section.

Each of the relatively rigid portions 62 is molded with an array ofholes 66 (shown, for example, as a longitudinal row of holes) openingtherethrough in substantially parallel directions (i.e., in theabove-defined pull direction) perpendicular to the mold plane when thepanel 60 is lying in the mold plane. Thus, the panel can be produced ina generally conventional injection mold and easily separated therefrom.Each relatively rigid portion 62 has a proximal end 68 and a distal end70; the rows of holes 66 extend from the distal ends of the portions 62for a major portion of the length thereof but terminate somewhat shortof the proximal ends of the portions 62 so that each portion 62 has ahole-free proximal region 72.

The applicator of FIGS. 13-17 also includes a second integral moldedplastic panel 74, again lying substantially in a mold plane when formedand being of rectangular configuration as seen in plan view in thatcondition. The panel 74 has an outer surface on which are integrallymolded rows of projections or bristles 76, generally perpendicular tothe last-mentioned mold plane (i.e., oriented substantially parallel toa common pull direction) when the panel 74 is lying in the mold plane,enabling the panel 74 to be molded in a generally conventional injectionmold and easily pulled from the mold. The bristles 76 are respectivelypositioned for register with the holes 66 of the outer panel. The innerpanel, in this embodiment, is formed of a material softer than that ofthe outer panel 60, and the bristles 76 are therefore softer and moreflexible than they would be if they were simply molded integrally withthe outer panel.

The inwardly facing surface of the outer panel 60 and the outwardlyfacing surface of the second or inner panel 74 are substantially flatwhen the panels are in the as-molded condition substantially lying inrespective mold planes as represented in FIGS. 13-15, to facilitatesuperposing the outer panel on the second panel and insertion of thesecond-panel bristles 76 through the outer-panel holes 66 as shown inFIG. 15, in the first step of assembling the applicator. The inwardlyfacing surface of the second panel 74 is molded to provide a pluralityof parallel ribs 78 of generally triangular cross-section, correspondingto the rigid portions 62 of panel 60 in number and orientation when thetwo panels are juxtaposed as shown in FIG. 15, with hinge portions 80formed integrally with and connecting adjacent ribs 78.

After the two panels have been initially brought together as shown inFIG. 15 with the flexible bristles 76 of the inner panel 74 extendingoutwardly through and beyond the holes 66 of the outer panel 60, the twopanels are curved or bent together about an extended longitudinal axisparallel to rib portions 62 so as to surround the axis and thereby to betransformed from the generally planar assembly of FIG. 15 to a generallycylindrical applicator 82, shown in FIG. 16, in which the ribs 62 of theouter panel 60, connected by hinges 64, constitute a shell orexoskeleton of sufficient rigidity to sustain the shape of theapplicator, surrounding a relatively soft inner core constituted of theinner panel 74 bent into a cylinder and filling the interior of theshell. The bristles 76, oriented substantially parallel to each otherwhen the panels lie substantially in their mold planes, radiateoutwardly from the applicator around the periphery thereof, projectingthrough the correspondingly oriented holes 66 to form a generallycylindrical brush bristle array.

As in the description of other embodiments of the invention, the term“relatively rigid portions” refers to portions of a molded plastic panelhaving sufficient rigidity to maintain the applicator as aself-sustaining structure when the panel is transformed from aninitially generally planar condition to a final, e.g. substantiallycylindrical, condition in which the relatively rigid portions surroundan extended longitudinal axis. The hinge portions interconnecting therelatively rigid portions are made sufficiently flexible to enable thepanel to be bent into the generally cylindrical configuration of thefinal applicator even though the relatively rigid portions are notthemselves bendable.

FIG. 16 is a cross-section of the assembled applicator 82 taken as alongthe line A-A of FIG. 13, through the portion of outer panel 60 in whichthe relatively rigid portions 62 have holes 66. FIG. 17 is a similarcross-section of applicator 82 taken as along the line B-B of FIG. 13,through the hole-free proximal regions 72 of portions 62. The innerpanel 74 does not extend proximally to these regions; instead, thelatter regions of the relatively rigid portions 62 of the outer panelare formed with generally triangular inwardly directed ribs 84. In thetransformed condition of FIG. 17, the regions 72 (which are free ofoutward projections or bristles, as well as being free of holes)cooperatively constitute the shank of the applicator wherein the ribs 84serve as a core. As shown, the outer diameter of the shank can besmaller than that of the bristle-forming portion of the applicator whenbent into a cylinder, and the proximal regions 72 of portions 62 can bespaced apart rather than connected by hinges 64.

The shank is inserted in a sleeve or hollow shaft of an applicatorhandle (not shown in FIGS. 13-17) which may be generally similar instructure and functions to that illustrated in FIG. 7 and describedabove, retaining the panel 60 in the cylindrical configuration of FIGS.16-17. Additional retainer structures (also not shown) may be providedto retain the distal end of panel 60 in the cylindrical shape.

In the embodiment of FIGS. 18 and 20-21, an initially generallyrectangular integrally molded plastic outer panel 90 has a plurality ofparallel rib portions 92 of outwardly convex cross sectioninterconnected by generally parallel and relatively flexible hingeportions 94 between the rib portions. The panel 90 has a distal end 98and a proximal end 100; in a first region 101 of the panel, extendingfrom the distal end for more than half the length thereof, rows of holes102 are formed in the ribs, but there are no holes in the remainingregion 103 of the panel adjacent the proximal end 100. The inwardlyfacing surface of panel 90 is substantially flat in region 101, while inregion 103 the inwardly facing surface of the panel is formed with ribs104 of generally triangular cross-section.

The embodiment of FIGS. 18 and 20-21 also includes an initiallygenerally rectangular integrally molded plastic inner panel 106 havingan initially flat outer surface bearing an array of outwardly projectingbristles 108 respectively positioned for register with, and insertionin, the holes 102 of the outer panel when the outer panel is superposedon the inner panel in the first step of assembly, shown in FIG. 18. Theinwardly facing surface of panel 106 is formed with plural parallellongitudinal ribs 110 of generally triangular cross-sectioninterconnected by parallel hinge portions 112.

Each of panels 90 and 106, as molded, lies substantially in a moldplane, while the holes 102 of panel 90 open in a common direction (pulldirection) perpendicular to the mold plane of panel 90, and theprojections (bristles) 108 of panel 106 project in a common directionperpendicular to the mold plane of panel 106, enabling the panels to bemolded in generally conventional injection molds and to be easilyseparable from the molds.

The proximal-to-distal length of inner panel 106 is equal to thecorresponding dimension of region 101 of outer panel 90. In a firstassembly step, panel 106 is placed in register with the region 101 ofpanel 90 as shown in FIG. 18, the flat inner surface of region 101facing the flat outer surface of panel 106 and the bristles 108 beingdisposed for insertion into the holes 102; the two panels are thenbrought together so that the bristles project through and outwardlybeyond the holes. Thereafter, the two panels are bent or curved togetherabout an extended longitudinal axis parallel to the ribs 92,transforming the initially generally planar panel array with itsparallel holes and bristles into a generally cylindrical applicator,having the last-mentioned axis as its geometrical axis, wherein thebristles radiate outwardly at locations distributed around the peripheryof the cylinder. The region 103 of panel 90 constitutes the shank of theapplicator and (as in the case of the applicator of FIGS. 13-17) may bereceived in a shaft or sleeve of an applicator handle or mascaracontainer cap (not shown in FIGS. 18-21) to retain the panels in thecylindrical configuration. Again, the outer diameter of the shank can beless than that of the bristle-bearing portion of the applicator whenbent into a cylinder, and the proximal, shank-forming regions of theribs can be spaced apart rather than hinged together.

Unlike the bristles 76 of the embodiment of FIG. 13, which are moldedintegrally with panel 74 (as illustrated, for purposes of comparison, inFIG. 19), the bristles 108 in the embodiment of FIG. 18 are tufts ofbrush fibers 114 (FIG. 20) inserted through adjacent holes 116 formed inpanel 106. FIG. 21, a fragmentary view of a portion of the inner surfaceof panel 106, illustrates the provision of these holes 116 in recessedportions 118 of the inner panel ribs 110. The provision of such tufts inapplicators of the invention will be further described below.

The integral, unitary molded plastic panel of the applicator of theinvention may alternatively be made sufficiently flexible throughout soas to be bendable into a cylinder with substantially continuous uniformsurface curvature. Such an applicator is shown in FIGS. 22-25, whereinthe panel 120 is a soft, flexible and generally rectangular elementhaving a multiplicity of soft bristles 122 formed on its outer surfaceand, in the as-molded condition, oriented in a common pull directionperpendicular to the mold plane in which the panel initially lies (FIGS.23 and 24). The proximal-to-distal side edges 124 and 126 of the panelare formed as longitudinally extending L-shaped flanges 128 and 130initially opening toward each other across the inner surface of thepanel.

To assemble the applicator of FIGS. 22-25, the panel is rolled or bentabout a longitudinal axis to form a cylinder 127 (FIGS. 22 and 25) withthe bristles projecting radially outwardly at locations distributedaround the cylinder periphery and the flanges 128 and 130 abutting eachother to form a longitudinal T-shaped ridge 132 enclosed within thecylinder.

A rigid, generally cylindrical molded plastic core 134, having a slot136 of T-shaped cross-section opening through and extendinglongitudinally from its distal end 138, is dimensioned to be insertedlengthwise into the cylinder 127 and to receive ridge 132 within slot136, thereby to serve as an internal support for the applicator and as aretainer holding the panel in the cylindrical configuration. The slot136 terminates some distance from the proximal end of the core 134,providing a shank portion 140 of the core for mounting in the shaft orsleeve of an applicator handle/mascara container cap (not shown).

A modified structure of this type is shown in FIGS. 26-29, wherein themolded, soft, flexible plastic panel 142, rectangular in plan, has thecross-sectional shape of a right-angled Z (FIG. 27). The upper and lowerlimbs of the Z, as molded, are flat portions respectively designated 144and 146, lying in parallel horizontal planes and connected by a verticalcentral septum 148 (the terms “vertical” and “horizontal” being usedmerely for convenience to designate relative orientations). A firstarray of soft molded plastic bristles 150 is formed on and projectsvertically upwardly from the upper surface of panel portion 144, while asecond array of soft molded plastic bristles 152 is formed on andprojects vertically downwardly from the lower surface of panel portion146. In addition, a first flat vertical longitudinal flange 154 projectsdownwardly from the outer side edge of panel portion 144 and a secondflat vertical longitudinal flange 156 projects upwardly from the outerside edge of panel portion 146.

Considering the “mold plane” of this panel as the two parallel planes ofpanel portions 144 and 146, and the “pull direction” as the directionperpendicular to those planes, it will be seen that in the as-moldedcondition of FIG. 27, both panel portions 144 and 146 lie substantiallyin the mold plane, while all other features of the panel (septum 148,bristles 150 and 152, and flanges 154 and 156) are oriented in the pulldirection. Hence, like the panels of the other embodiments of theinvention herein described, the panel 127 may be readily produced in agenerally conventional injection mold and easily separated therefrom.

To assemble an applicator using panel 127, the two panel portions 144and 146 are bent or rolled through 180° in opposite directions about anextended longitudinal axis (coincident, in this case, with the geometriclong axis of septum 148) such that the bristles 150, 152 projectoutwardly and the flanges 154 and 156, both inverted from their initialorientations, respectively lie flush against opposite sides of theseptum 148. The panel is thereby transformed into a cylinder 158 withoutwardly radiating bristles distributed around its periphery and acentral internal longitudinal wall 160.

A rigid plastic core 162, having a cylindrical shank portion 164 at itsproximal end and a pair of parallel prongs 166 projecting distallytherefrom, serves as an internal support for the cylinder 158. The twoprongs of the core, inserted longitudinally into the proximal end of thecylinder through the openings between the cylinder and wall 160, projectbeyond the distal end of the cylinder; the outer surfaces of the distalends of the prongs, as indicated at 168, are shaped with an annulargroove and taper to constitute a snap-fit seat for a plastic cap 170having an internal annular ridge 172 engageable with groove 168. Afterthe core prongs have been inserted entirely through the cylinder 158,the cap 170 is snap-fitted on the prong ends, cooperating therewith toretain the panel 142 in the cylindrical shape by holding the prongs ingripping relation to the wall 160 and thereby securing the flanges 154and 156 against the septum 148.

FIGS. 30 and 31 illustrate another modified embodiment of the invention,in which an integral molded plastic panel 174 made of soft flexiblematerial and rectangular in shape as molded (i.e., when lyingsubstantially in a mold plane), bearing on its outer surface amultiplicity of molded plastic bristles 176 oriented in a common pulldirection perpendicular to the mold plane, is provided with a pair oflongitudinal stiffeners 178 respectively secured to and extending alongits opposite side edges, in opposed relation to the bristle-bearingsurface of the panel. These stiffeners are molded of relatively rigidplastic and are generally hemispherical in cross-section, with flatsurfaces 180 facing laterally outward (FIG. 30) in the as-moldedcondition of the panel. The stiffeners may be insert molded on the panelor secured thereto by assembly. Each of the stiffeners extends to thedistal end 182 of the panel, and also includes a shank portion 184projecting beyond the proximal end 186 of the panel.

To assemble the applicator, the panel 174 is bent or rolled about anextended longitudinal axis parallel to the stiffeners 178 until the flatsurfaces of the stiffeners abut each other, at which point the panel iscylindrical in configuration and the bristles 176 radiate outwardlytherefrom and are distributed around the periphery of the cylinder (FIG.31). The shank portions 184 cooperatively constitute a shank which isinserted in a shaft or sleeve of an applicator handle (not shown) tohold the proximal ends of the stiffeners together, while a clip 186 ofstiff plastic is inserted into the distal end of the applicator to holdthe distal ends of the cylinder together, such that the panel is held incylindrical shape.

A still further configuration for the integral molded plastic panel ofthe invention is as a narrow, elongated flexible band of soft materialthat, as molded, lies substantially in a mold plane with a surfacebearing molded projections or bristles extending therefrom substantiallyin a common pull direction transverse to the plane. In assembly, theband is wound helically about an extended longitudinal axis with theprojection-bearing surface facing outwardly to form a conical,frustoconical, or cylindrical applicator.

One specific embodiment including such a band of soft, flexible materialis shown in FIGS. 32 and 33. The band 200 in this embodiment includestwo portions, respectively designated 202 and 204, which as moldedextend substantially in parallel but offset planes (mold plane) and aredisposed substantially end to end with their adjacent ends connected bya post 206 extending perpendicular to the parallel planes. The portion202 has a multiplicity of bristles 208 formed on a surface thereoffacing away from portion 204, and portion 204 has a multiplicity ofbristles 210 formed on a surface thereof facing away from portion 202;the bristles 208 and 210, as well as the post 206, are orientedsubstantially in a common pull direction perpendicular to the parallelplanes with the bristles on the two band portions respectively pointingin opposite directions when the panel is in as-molded condition of FIG.32.

A generally cylindrical core 212 of rigid molded plastic, including aproximal portion or shank 214 and an extended distal portion 216, servesas a structural support for the applicator made from the band 200. Thedistal end of portion 216 is formed as a clip 218 for receiving andgripping the post 206 at the midpoint of band 200. With the postinserted in and held by the clip, the core is twisted about its longaxis 220 as indicated at 222 in FIG. 33 so as to cause the two portionsof band 200 to wind helically around core portion 216, therebytransforming the initially planar band into an applicator wherein theband is bent to surround the extended longitudinal core axis 220 in agenerally cylindrical configuration, with turns of the two band portions202 and 204 alternating and with the bristles on both band portionsradiating outwardly from the core axis 220. The shank portion 214 of thecore may be mounted in an applicator handle, e.g. of the general typeshown in FIG. 7, described above, with the outer ends of the two bandportions 202 and 204 suitably anchored.

FIGS. 34-36 illustrate a modified embodiment of the invention in whichthe panel is again a band 224 of soft, flexible plastic material, lyingsubstantially in a mold plane in as-molded condition and bearing on onesurface a multiplicity of soft, flexible plastic bristles 226 moldedintegrally with the band. The bristles 226, in the as-molded conditionof the band, are oriented substantially in a pull direction transverse(perpendicular) to the mold plane (FIG. 35). The band 224 differs fromthe band 200 of FIGS. 32-33, however, in being a single continuous bandportion adapted to be secured at one end 228 to the distal extremity ofa core and to be wound helically as a single strand around the core.

This embodiment may utilize the core 212 described above with referenceto FIGS. 32 and 33, with the clip 218 modified to grip and retain theend 228 of the band 224. As shown in FIGS. 35 and 36, with the band endinserted in and held by the clip, the core is twisted about its longaxis 220 so as to cause the band 224 to wind helically around coreportion 216, transforming the initially planar band into an applicatorwherein the band is bent to surround the extended longitudinal core axis220 in a generally cylindrical configuration, with the bristles 226radiating outwardly from the core axis 220. The shank portion 214 of thecore may be mounted in an applicator handle (not shown) as describedabove, with the outer end of the band 224 suitably anchored.

Alternatively, as shown in FIG. 37, the band-supporting core may be ametal wire 230 secured at its distal end to the end 228 of the band. Theband is then helically wound around the core wire to constitute anapplicator with outwardly radiating bristles 226, and the wire ismounted in an applicator handle (not shown).

A wide variety of arrangements of bristles on the surface of the band200 or 224 may be employed, instead of the single row of bristles ofFIGS. 32-37. Two non-limiting examples are illustrated in FIGS. 38 andFIG. 39, which respectively show plural rows of bristles 208 a, 208 band 208 c of differing heights on a band portion 202, and a double rowof staggered bristles 226 a on band 224.

Yet another embodiment of the applicator of the invention in which thepanel is a narrow bristle-bearing band is shown in FIGS. 40-48. The band232 in this embodiment is molded around a reinforcing wire 234 of metal(FIG. 43) which extends longitudinally within, and is entirely laterallysurrounded by, the band. A multiplicity of bristles 236, integrallymolded with the band, are disposed along the length of the band,projecting from one surface thereof. The band may be made of a soft,flexible plastic material, using a generally conventional injection moldin which the wire 234 is positioned before the plastic material isintroduced; in the as-molded condition, the band 232 lies substantiallyin a mold plane and the bristles 236 are oriented substantially in acommon pull direction transverse (perpendicular) thereto.

To transform the wire-reinforced band into an applicator, the band isinitially held at its midpoint 238 (FIGS. 40 and 41), which becomes thetip of the applicator, and the two legs 240 and 242 of the band are thentwisted around each other in the same way that the legs of the wire coreof a conventional twisted-in-wire mascara brush are twisted, so that theband is bent to surround the extended longitudinal axis of twisting withthe bristles radiating outwardly from that axis. The reinforcing wire234 within the band is selected to be stiff enough to hold the twistedshape. The proximal ends of the legs, twisted together, may then bemounted in an applicator handle (not shown).

Steps in the manufacture of a specific exemplary mascara brush of theembodiment of FIGS. 40-43 are illustrated schematically (not all to thesame scale) in FIGS. 44-48.

FIG. 44 shows the as-molded band 232, lying substantially in a moldplane, with the wire 234 extending longitudinally therethrough andbristles projecting from the band substantially in a common pulldirection transverse to the mold plane. In this example, the band ismolded in two tandem portions 232 a and 232 b spaced apart at themidpoint 238 of the wire. Portion 232 a bears a set of uniform longmolded bristles 236 a substantially perpendicular to the mold plane,while portion 232 b bears two rows of uniform shorter molded bristles236 b inclined at small angles to the perpendicular and to each other,thereby forming a V. Although the bristles 232 b are thus inclined tothe pull direction, they are nevertheless substantially oriented in thepull direction because the angle of inclination is sufficiently small soas not to interfere with separation of the mold plates and removal ofthe molded panel (band) from the mold.

FIG. 45 is a complete side view, at a reduced scale, of the band andwire of FIG. 44, still in the as-molded condition. It will be noted thatthe band portions 232 a and 232 b terminate short of the proximal ends244 of the wire.

The wire 234 is bent at its midpoint 238 through 180° as shown in FIG.46, so that the two legs 240 and 242, respectively having band portions232 a and 232 b, extend parallel to each other with the bristles 236 aand 236 b projecting in opposite directions. Thereafter, as illustratedin FIG. 47, the wire is twisted about a longitudinal axis into anincreasingly tight helix, and the bristles are correspondinglydistributed in a helical pattern, wherein alternate turns areconstituted of bristles 236 a and bristles 236 b.

The final applicator 246, shown in FIG. 48, includes a proximal twistedwire shank portion 248 mountable in an applicator handle (not shown) anda brush portion 250 wherein the bristles 236 a and 236 b, in alternatinghelical patterns, radiate outwardly. FIG. 48A is a flow chart of theprocess of transforming an as-molded panel (I) of the type of FIG. 45through successive stages of bending (II) and twisting (III) until afinal applicator (IV) is achieved, with the direction of bendingindicated by arrow B and the direction of twisting indicated by arrow T.In FIG. 48A, band portions 232 c and 232 d with bristles 236 c and 236 dcorrespond to band portions 232 a and 232 b with bristles 236 a and 236b in FIG. 45; wire 234 a with midpoint 238 a, legs 240 a and 242 a, andends 244 a corresponds to wire 234 with midpoint 238, legs 240 and 242and ends 244 in FIG. 45; and shank and brush portions 248 a and 250 acorrespond to portions 248 and 250 in FIG. 45, with some dimensionalalterations.

A modification of this applicator is illustrated, in successive stagesof bending, in FIGS. 49 and 50, which respectively correspond to thebending stages represented in FIGS. 46 and 48. In the modifiedapplicator, the bristles 236 a′ are not of uniform length, but becomeprogressively shorter from about the midpoint of the bristle array tothe distal end of the brush, and the bristles 236 b′ are also not ofuniform length but become first progressively shorter, thenprogressively longer, and finally progressively shorter again,proceeding toward the distal end of the brush. As a result, when thewire shank portion 248′ is fully twisted, the bristle tip envelope orprofile is as shown in FIG. 50. The bristles may be molded with thesediffering lengths, or they may be molded with uniform lengths as shownin FIG. 44 and then trimmed or cut before or after the band is bent.

Another applicator embodying the invention and employing a band 232 asshown in FIG. 40 is illustrated in FIG. 51. In this embodiment, thewire-containing band is wound in a single resilient, springlike helix252, with its bristles 236 (not individually shown in FIG. 51)projecting radially outwardly with respect to the axis of the helix; ametal shank 254, secured at its distal end to the distal end 256 of thehelix 252, extends coaxially through the helix to the proximal end 258of the helix. The applicator of FIG. 51 also includes an actuator 262having a rigid, hollow, open-ended outer stem 264 and a rigid inner stem266 extending entirely through the hollow outer stem, coaxiallytherewith, so as to be movable, relative to the outer stem, linearlyalong and rotatably about their common axis, which is coincident withthe axis of the helix. The proximal end 258 of the helix is fixedlymounted on the distal end of the outer stem, while the shank 254 isattached at its proximal end to the distal end of the inner stem.Secured to or formed integrally with the proximal end of the outer stemis an enlarged well 268 into which the inner stem 266 projects; anenlarged head 270 secured to the proximal end of the inner stem isreceived within the well, and is manually translatable along androtatable about the common axis of the inner and outer stems, relativeto the well.

In this device, manual rotation (arrow 272) of the head 270 relative tothe well is imparted to the distal end of the helix 252 through theinner stem and shank, and since the proximal end of the helix isanchored to the outer stem, such rotation varies the pitch and outerdiameter of the helix. Manual movement (arrow 274) of the head back andforth relative to the well along the stem axis, acting on the distal endof the helix through the inner stem and shank, causes the helix tocontract or lengthen axially, varying the pitch between helical turns ofthe bristle array.

Various further modifications of the applicator of FIGS. 34-36 areillustrated in FIGS. 52-59F. The applicator in each of these modifiedembodiments includes a rigid plastic core (corresponding to core 212 ofFIG. 34, and having a shank portion and a distal portion respectivelycorresponding to portions 214 and 216 of core 212, in position andfunction) formed at its distal end with a clip (corresponding to clip218 of FIG. 34), and a band of soft, flexible plastic material(corresponding to band 224 of FIG. 34) lying substantially in a moldplane in as-molded condition and bearing on one surface a multiplicityof soft, flexible plastic bristles (corresponding to bristles 226 inFIG. 34) molded integrally with the band. These elements are so arrangedthat the clip grasps and secures the midpoint of the band (rather thanon end of the band, as in FIG. 34) and the portions of the band oneither side of the midpoint are wound radially around the distal portionof the core to constitute an applicator wherein the bristles extendradially outwardly with respect to the core.

In the applicator shown in FIGS. 52-54, the core 212 a is formed with acurved distal portion 216 a rather than an axially rectilinear distalportion as in FIG. 32. The clip 218 a grips the midpoint of the band 224a (FIG. 53), which is otherwise similar to the band of FIG. 32, and theportions of the band 224 a extending therefrom are wound helicallyaround the distal portion 216 a with the bristles 226 a projectingoutwardly therefrom (FIG. 54).

As shown in FIGS. 52A, 53A and 54A, the core 212 a may be replaced by ametal wire core 230 a (like core 230 of FIG. 37) which is malleable, theterm “malleable” being used herein to refer to a metal article which iscapable of being bent and/or twisted and of holding a shape into whichit is thus bent and/or twisted. The band 224 a, secured at its midpointto the distal end of core 230 a (FIG. 52A), is wound helically aroundthe core (FIG. 53A) in the same manner as in FIGS. 52-54, and the wirecore is bent (FIG. 54A) into a desired shape, e.g. a curved shapecorresponding to the curve of the core in FIGS. 52-54.

FIGS. 55-57C show an alternative form of band 224 b having successiveportions with different profiles and/or bristle arrangements arranged intandem along its length. In a first portion 276, shown in section inFIG. 56A and in plan view in FIG. 57A, the band itself is formed with anoutwardly-facing channel 278 and a single row of bristles 280 ofrectangular cross-section project outwardly therefrom. The secondportion 282 of the band (FIGS. 56B and 57B) has an outwardly crownedprofile bearing two longitudinal rows of bristles 284 of round orelliptical cross-section, with the bristles of one row divergingoutwardly from the bristles of the other row. The third portion 286 ofthe band, illustrated in FIGS. 56C and 57C, is divided by a longitudinalslot 288 into two parallel legs 290 each bearing a single row ofbristles 292 of triangular cross-section, the bristles on both legsextending parallel to each other.

These differing band portions are non-limiting examples of possiblevariations in bands of the general type shown at 224 in FIG. 34. Theyillustrate variations in band profile and width, and bristle shape;bristle distribution and size can also vary, to impart desiredcosmetic-transporting and/or applying characteristics to the producedapplicator. These and/or other differing configurations and bristlearrangements may be combined, as shown, in a single band for use in anapplicator, or a band may be provided with any one of suchconfigurations and arrangements along its entire length.

Similarly, as exemplified by the applicator shown in FIGS. 58-59F, therigid core need not be of uniform, circular cross-section. The core 212b has a distal portion 216 b with a first circular cross-section (FIG.59D) near the clip 218 b, a second, smaller circular cross-section (FIG.59F) near the shank portion 214 b, and an intermediate portion of smallsquare cross-section (FIG. 59E). As one further alternative, theintermediate cross-section may be triangular (not shown) rather thansquare. Again, the illustrated variations of core profile are merelyillustrative of possible variations, and the core distal portion mayeither vary from point to point along its length as shown, or may have auniform non-circular cross-section throughout.

FIG. 59 additionally shows the varying-profile core 212 b as associatedwith a band 224 c that varies in width, profile shape and arrangement ofbristles 226 c along its length, in ways generally similar to the band224 b of FIGS. 55-57C. Such variations are illustrated in cross-sectionin FIGS. 59A, 59B and 59C. Alternatively, the core 212 c could be usedwith a band, e.g. of the type shown at 224 a in FIGS. 52-54, that isuniform throughout its length.

In the embodiments of the invention thus far described, wherein aplastic panel is molded with integral features such as openings orprojections, the as-molded panel lies in a mold plane and the featuresare oriented substantially in a common pull direction perpendicular tothe mold plane, thereby facilitating opening of the mold and separationof the molded panel therefrom, as explained above. Within the broaderscope of the invention, however, it is possible to achieve the sameadvantages when the features, or some of the features, are projectionsoriented (i.e., extending from an edge of the panel) in the mold plane.In such case, the mold cavity defined by the facing mold plates includesportions, for forming the latter projections, defined by cooperatingrecesses in each of the mold plates, so that there is no interferencebetween these projections and the mold plates as the mold platesseparate.

One example of a molded plastic panel of this type, shown at 296 inFIGS. 60 and 61, is similar to the panel 232 of FIG. 40 in being moldedaround an elongated malleable metal insert 298. The plastic panel body300 completely laterally surrounds the insert 298, and is illustrated asbeing rectangular in cross-section with first and second opposed panelsurfaces 302, 304 and first and second opposed side edges 306, 308between the surfaces. Features in the form of plastic projections 310,314 respectively extend from the opposed panel surfaces in directionssubstantially perpendicular thereto, while additional plasticprojections 316, 318 respectively extend from the opposed panel edges indirections perpendicular to the projections 310, 314.

The panel 296, which (like panel 232 of FIG. 40) has the shape of anarrow band, may be formed by molding between mold plates in the mannerschematically illustrated in FIG. 1 and described above with referencethereto, the insert being placed in the mold cavity before the moldingoperation. The mold plane is indicated by line PL-PL in FIG. 61. As willbe understood, recesses for forming the projections 310 and 314 arerespectively provided in the upper and lower mold plates and extendsubstantially perpendicular to the mold plane, while the lateralprojections 316 and 318, lying in the mold plane, are each defined bytwo cooperating recesses respectively provided in the two mold platefaces and extending in the mold plane. Thus, when the plates separate inthe common pull direction D (FIG. 1), opening of the mold and removal ofthe molded panel 296 is not hindered by interference between any of theformed projections and the plates.

The panel 296, which is shown in FIG. 60 as bent into a U-shapedconfiguration, may be further bent and/or twisted so as to betransformed into cosmetic applicators having a variety ofconfigurations. Examples of such applicators are illustrated in FIGS.62-66.

In the applicator 320 of FIG. 62, the panel is bent into a U-shapesimilar to that of FIG. 60 but one leg of the U has multiple furtherbends 322 imparted thereto. The metal insert 298 has two exposed endsrespectively extending beyond the ends of the plastic panel; theseexposed ends are placed side by side and twisted together to form ashank 324 for retaining the panel in the shape into which it has beentransformed by bending and for mounting the applicator in a handle.

FIG. 63 illustrates an applicator 326 in which the panel is again bentinto a U, with one leg 328 repeatedly twisted along its axis and theother leg 330 bent into the shape of an open helix. Again, the metalinsert has exposed opposite ends which are twisted together to form ashank 332 for the same purposes as shank 324 of applicator 320 describedabove.

In the applicator 334 of FIG. 64, the band 296 is first formed into a U,and one leg 336 of the U is then knotted over the other leg 338 bybending to form a loop. Exposed ends of the metal insert are twistedtogether to form a shank 340. The applicator 342 of FIGS. 65 and 66 hasa succession of criss-cross bends 344 imparted to the legs of a U intowhich band 296 is initially bent, and once more the exposed ends of themetal insert are twisted together to form a shank 346.

FIGS. 67 and 68 illustrate a modified molded plastic panel 296 a similarto but wider than the panel 296 of FIGS. 60-61, having an elongatedmalleable metal insert 298 a (correspondingly similar to but wider thanthe insert 298 of FIGS. 60 and 61) completely laterally surrounded bymolded plastic panel body 300 a. This panel 296 a bears four rows ofprojections 310 a extending from its upper surface 302 a and four rowsof projections 314 a extending from its lower surface 304 a rather thanthe single rows of projections 310 and 314 in the panel 296, althoughthe lateral edge projections 316 a and 318 a (initially lying in themold plane) are still single rows to permit separation of the moldplates in the common pull direction. As shown, different rows ofprojections 310 a and 314 a may be somewhat divergent, but still areoriented substantially in the common pull direction so long as theirangles of divergence are sufficiently small, and the projections aresufficiently flexible, to enable ready separation of the mold plates andremoval of the panel from the mold at the end of the molding operation.After molding, the panel is bendable (as indicated at 348 in FIG. 68)and twistable (as indicated by twist 350 and reverse twist 352 in FIG.68) so that it can be transformed into an applicator of any of a varietyof configurations, with the relative orientation of at least some of theprojections altered by the twisting and bending. The projections areillustrated as bristles, but other forms of molded features can beprovided.

FIGS. 69 and 70 illustrate another modified molded panel 296 b,generally similar in configuration and dimensions to the panel 296 a ofFIGS. 67-68 but differing therefrom in that the single wide metal insert298 a is replaced by a plurality of parallel wire-shaped elongated metalinserts 298 b (two being shown in the drawings). Again, the opposedsurfaces 302 b and 304 b respectively bear multiple rows of projections310 b and 314 b oriented substantially in a common pull direction, whilethe edges bear single rows of projections 316 b and 318 b initiallylying in the mold plane. Like the panel 296 a, panel 296 b may be bent(as indicated at 354 in FIG. 70) and twistable (as indicated by twist356 and reverse twist 358 in FIG. 70) so that it can be transformed intoan applicator of any of a variety of configurations, with the relativeorientation of at least some of the projections altered by the twistingand bending. Once more the projections are illustrated as bristles, butother forms of molded features can be provided.

FIGS. 71-83 show further embodiments of the applicator of the inventionwhich, like the embodiments of FIGS. 60-70, are produced from plasticpanels molded around elongated malleable metal inserts and havingprojections lying in the mold plane as well as projections orientedsubstantially in a common pull direction. In these embodiments, however,the metal insert is bent to form a laterally as well as longitudinallyextended support before the plastic is molded, so that the molded paneldoes not have the configuration of a band (as in FIGS. 60-70) but atleast in portions has substantial width, being transformed into anapplicator by a bending operation (e.g., a folding operation) after themolding step.

A first such applicator, illustrated in FIGS. 71-75C, has a panel formedaround an elongated malleable metal insert 360, which may be similar tothe insert 298 of FIGS. 60-61 but is initially bent into a planardouble-looped configuration, forming an extended support 362 as shown inFIG. 71, with the two ends of the insert remaining untwisted. Thisinsert is then placed in a mold cavity and plastic is molded around itto produce the projection-bearing plastic panel 366 of FIG. 72, whereinprojections 368 extending from one surface of the panel are orientedsubstantially in a common pull direction, and projections 370 extendingfrom edges of the panel lie initially in the mold plane indicated byline PL-PL in FIGS. 73A, 73B and 73C. As seen in FIGS. 72 and 73A-73C,the mold cavity is so shaped that the molded plastic completelysurrounds the insert 360 in distal loop 372 but leaves a central openingin the panel, while spanning proximal loop 374 to provide a wide portionof the panel, and also spanning the gap between spaced parallel portions376 of the insert intermediate the loops. Finally, the panel is bent(folded) about a longitudinal center line 378 (FIGS. 74-75C) and theexposed wire is twisted to form the shank, being thereby transformedinto an applicator 380 in which the relative orientations of many of theprojections are changed from the as-molded state.

In the applicator 382 of FIGS. 76-79, an elongated malleable metalinsert 384 is bent to form a single elongated and parallel-sided planarloop, with the ends of the insert twisted together to provide a shank386, prior to molding. The bent insert is placed into a mold cavity, anda generally planar plastic panel 388 is molded around it, spanning theentire loop and bearing projections 392 oriented substantially in acommon pull direction as well as projections 394 lying in the mold planePL-PL (FIG. 77). The molded panel is bent around a longitudinal centerline to form an applicator of generally curved cross-section as shown inFIG. 79.

The panel 396 of the applicator 398 of FIGS. 80-83 is molded with aright-angled Z-shaped cross-section similar to that of panel 142 of FIG.27. The elongated malleable metal insert 400 in this embodiment isformed, prior to molding of the panel, into a single straight-sidedplanar loop corresponding to that of the above-described panel shown inFIG. 76, and placed into a mold cavity where the plastic panel ofZ-shaped cross section is formed, spanning the loop and bearing bothprojections 402 oriented substantially in a common pull direction andprojections 404 lying in the mold plane PL-PL (FIG. 81). The panel isthen transformed, by bending about a longitudinal center line, into thefinal applicator configuration of FIGS. 82-83.

FIGS. 84-91 illustrate another applicator 406, also embodying theinvention. Like the applicators of FIGS. 76-79 and 80-83, thisapplicator includes an elongated malleable metal insert 408 which isfirst bent into a single elongated and straight-sided planar loop andthen placed in a mold cavity where a plastic panel 412 is formed,spanning the loop. Afterwards, its ends are twisted together to form ashank 410. The panel 412 differs from those of the embodiments justdescribed, however, in that the features formed by molding are notprojections but openings 414, oriented in a common pull direction (theorientation of an opening being that of the axis between its open ends)and elongated transversely so as to divide the loop-spanning portion ofthe panel into a multiplicity of spaced parallel bars 416 spanning theloop from side to side thereof. After molding, the panel looped insertand panel 412 are first bent (folded) along a longitudinal center line418 (FIGS. 85-88) with the effect of folding the bars 416 at theirmidpoints into parallel projections. A final downward bend imparted tothe distal end 420 of the loop completes the transformation of the panel414 into the comb-like applicator shown in FIGS. 89-91.

A still further applicator 422, illustrated in FIGS. 92 and 93, has anelongated malleable metal insert 424 bent to form a planar U with tworuns of the insert constituting each leg of the U, and the ends of theinsert twisted to form a shank 426. This insert is placed in a moldcavity where a layer of plastic 428 is molded around each run of theinsert without spanning any gap between runs, and flocking 430 isapplied to the molded plastic. Alternatively, as FIG. 94 shows, theflocking 430′ may be applied and adhered directly to the surfaces of theinsert 424, omitting the molding step and the plastic layer. Theflocking, in these applicators, serves as an alternative to featuressuch as projections or openings molded in a plastic panel.

As mentioned above, another alternative to the molding of plasticprojections or bristles integrally with the panels is the attachment oftufts of bristles to the panels. Examples of bristle-attachingprocedures are illustrated in FIGS. 95-103.

In FIGS. 95-97, 34′ designates a limb of a panel of the general typeshown in FIGS. 5-7 but molded without projections. To provide a row oftufts of bristles along this limb, a plurality of parallel elongatestrands 432 of bristle fibers such as nylon fibers are disposed beneaththe limb 34′, extending parallel thereto. A needle 434 with a hooked end436 is passed through the limb, from the side opposite to the strands offibers, so that the hooked end engages the fibers (FIG. 95). The needleis then pulled back up through the limb, bringing a loop 438 of thefiber strands with it. When the loop 438 reaches a sufficient heightabove the limb, the hook is disengaged and moved along the limb to theintended location of another fiber loop. These steps are repeated untila desired number of spaced loops 438 has been provided along the limb(FIG. 96). Finally, the tops of the loops are trimmed off (FIG. 97),leaving an array of tufts 440 of bristles projecting upwardly from thelimb.

The procedures shown respectively in FIGS. 98-100 and 101-103 areillustrated as used with an applicator of the type shown above in FIGS.18 and 20-21, but may be adapted to many embodiments of the invention.Thus, in FIG. 98 there is shown one of the ribs 110 of the inner panel106 of the applicator of FIGS. 18 and 20-21, with a set of elongated,generally parallel strands 442 of nylon or other bristle fiber disposedalong and above the apex of the rib. As in the procedure of FIGS. 95-97,hooked needle 444 is passed upwardly through the panel rib to engage thefiber strands (FIG. 98) and pull a loop 446 of the strands back downthrough the rib until the loop projects from the flat lower surface 106a of the panel 106. These steps are repeated along the length of therib, and then along the length of each other rib of the panel 106, toprovide an array of loops 446 (FIG. 99) projecting from the panelsurface 106 a; the ends of the loops are then trimmed off (FIG. 100),leaving an array of tufts of fibers.

In the alternative procedure of FIGS, 101-103, a set of elongatedparallel strands of bristle fibers 448 is disposed beneath the flatlower surface 106 a of panel 106, parallel to one of the ribs 110, andis kept in place by a succession of spaced holders 452 spaced below thepanel surface 106 a. A hooked needle 454 is inserted downwardly throughthe last-mentioned rib 110 to engage the strands and pull them upwardlythrough the rib, forming a loop 456 above the rib; loop 456 mayoptionally be twisted during formation, as indicated at 457 in FIG. 101.As these steps are repeated along the rib, a retaining strand 458 isthreaded through the successively formed loops 456, which, if initiallytwisted, may optionally be untwisted after the retaining strand passesthrough them, as indicated at 459 in FIG. 102. Finally, the fibers aretrimmed at a location 460 below panel surface 106 a (FIG. 102), leavingan array of fiber tufts 462 projecting through that surface (FIG. 103).

In each of the foregoing procedures, if the panel 106 is formed withholes 116 (FIG. 21) during the molding operation, the needle 444 or 454is simply passed back and forth through each of these holes insuccession, establishing a tuft of fibers at the location of each hole.If there are no such holes, the needle is designed to pierce the panel106 as it is initially inserted therethrough at each tuft-forminglocation.

The invention additionally contemplates the provision of applicatorshaving projections (bristles) having any of a variety of differentcross-sections. As one exemplary but non-limiting alternative toconventional cylindrical-cross-section molded bristles, the bristles maybe elliptical in cross-section and oriented with their longcross-sectional axes at any desired angle from 0° to 90° relative to thedirection of wiping, i.e., the direction in which the applicator iswithdrawn from a mascara container while being engaged by a wiperelement (to remove excess mascara) in the container neck.

An illustrative embodiment of an applicator of the inventionincorporating elliptical-cross-section bristles is illustrated in FIG.104. In this applicator, which is of the general type shown in FIGS. 5-7above, the bristles 464 are, as stated, elliptical in cross-section, andare oriented with the long axes of their elliptical cross-sections at90° to the long axis of the applicator, which is parallel to the wipingdirection represented by arrow 466. Thus, they are relatively flexiblein the direction in which they pass through the wiper orifice,facilitating the wiping operation. When the applicator, laden withmascara, is brought to a user's eyelashes, however, the direction ofapplication (arrow 468) is perpendicular to the direction of wiping. Thelong axis of the bristle cross-section is parallel to this direction ofapplication, so that (as desired for applying mascara and combingthrough the lashes) the bristles are more rigid when passing through thelashes than they are when passing through the wiper.

In FIG. 104, each limb 34″ of the applicator panel bears two parallelrows of bristles, but the rows of bristles on adjacent limb arealternating or staggered. FIG. 105 illustrates another, otherwisesimilar applicator, in which the rows of elliptical-cross-sectionbristles 464′ on adjacent limbs 34′″ are aligned with each other. FIG.106 illustrates schematically the bristles 464′ of the applicator ofFIG. 105 passing through the eyelashes of a user to apply mascara.

FIG. 107 shows a band-shaped panel 470 of the same general type as thatof FIG. 40, but with molded projections (bristles) 472 having ellipticalcross-sections. When this panel is twisted to form a helix and therebyto constitute an applicator 474 as shown in FIG. 108, the bristles 472are so oriented that the long axes of their elliptical cross-sectionsare at 90° to the wiping direction (arrow 476), with the same effects asin the case of the applicators of FIGS. 104 and 105. More generally,bristles with non-circular (e.g. elliptical) cross-sections may beprovided on applicators such as mascara brushes generally, to enhancethe performance of wiping, applying, combing and/or other functionsthereof.

It is to be understood that the invention is not limited to the featuresand embodiments hereinabove specifically set forth, but may be carriedout in other ways without departure from its spirit.

What is claimed is:
 1. A molded plastic applicator for mascara,comprising: (a) an integral molded plastic panel lying substantially ina mold plane when formed and bent out of the mold plane to surround anextended longitudinal axis; and (b) a plurality of bristles moldedintegrally with the panel, oriented substantially in a common pulldirection transverse to the mold plane when the panel lies in the moldplane and oriented substantially radially of the longitudinal axis indirections distributed around the axis when the panel is bent to snuglysurround the axis so as to form a complete brush.
 2. An applicator asdefined in claim 1, further including a retainer holding the panel bentout of the plane in surrounding relation to the axis.
 3. An applicatoras defined in claim 1, wherein the panel comprises a plurality ofrelatively rigid portions interconnected by relatively flexible hingeportions to enable bending of the panel out of the mold plane tosurround the longitudinal axis without substantial deformation of therelatively rigid portions.
 4. An applicator as defined in claim 3,wherein the panel further includes a hub portion in register with thelongitudinal axis, which is transverse to the mold plane; the relativelyrigid portions comprise a plurality of limbs extending radially from thehub portion when the panel is lying substantially in the mold plane,each limb having a free end and a second end; and the hinge portionsrespectively connect the second ends of the limbs to the hub portion ofthe panel such that the limbs are bendable relative thereto so as to beparallel to and surround the axis.
 5. An applicator as defined in claim4, wherein the limbs respectively have surfaces facing away from theaxis when the limbs surround the axis, and said multiplicity of bristlesare projections formed on and extending from said surfaces of saidlimbs.
 6. An applicator as defined in claim 5, further including a stemand a retainer that engages the free ends of the limbs to hold them insurrounding relation to the stem.
 7. An applicator as defined in claim4, wherein each limb has a bristle-free end portion, the bristle-freeouter portions of the folded limbs cooperatively constituting a shankportion adapted to be inserted in the open distal end of a hollow shaftfor retaining the limbs in a folded position.
 8. An applicator asdefined in claim 1, wherein the panel is bent into a substantiallycylindrical shape with the longitudinal axis as the geometric axis ofthe cylinder.
 9. An applicator as defined in claim 1, wherein the panelcomprises a hub portion in register with the longitudinal axis and aplurality of limbs extending radially from the hub portion when thepanel lies substantially in the mold plane, each limb having a free endand a second end bendably connected to the hub portion such that thelimbs are bendable relative to the central portion so as to be parallelto the axis thereby to surround the axis.